High Access Solutions

By Alison Trendell, Goracon

“Climbing support and lift systems benefit the industry by lowering the maintenance time necessary per tower and by increasing the productivity and effectiveness of a single service crew”
-Goracon

Change in the Winds – New Federal Attitude Towards Alternative Energy
The wind power industry may begin to see some serious expansion with the federal government's new commitment to alternative energy. The feasibility of implementing wind parks is being considered for areas all over the United States. With the recent passing of the economic stimulus package, significant grant money has become available and coalitions and colleges within the wind initiative are avidly pursuing grants for wind energy training programs. In addition, the new $787 billion stimulus bill reportedly extends the Production Tax Credit (PTC) through 2012.

The federal focus on alternative energy is very encouraging for current wind energy investors and will likely spark interest from new investors looking to be a part of the energy initiative. When setting a course for the future of wind power, staying on the cutting-edge of efficient wind power generation will be key. One major aspect in productivity is the speed at which maintenance crews are able to complete their work, keeping wind towers running in optimal, energy-producing condition. Since wind power is a "Work at Height" industry, where the majority of tower maintenance must be performed at a height of over 200 feet, the safety and security of wind tower service professionals is extremely important.

Typical Tower Maintenance and "Work at Height" Hazards
The service necessary to maintain a tower is very similar to that of a standard steam-powered electrical generator. The oil needs to be changed on a regular basis, routine electrical measurements must be made and the bearings need occasional replacement. All of these tasks are performed at an extreme height. Hazards in this "Work at Height" industry are sometimes underestimated and workers may experience a false sense of security when working inside enclosed towers, not exposed to the outside elements, as in other "Work at Height" professions such as servicing communication towers.

The numerous hazards in this "Work at Height" industry includes potential injury to all body parts engaged while climbing a tower, such as knees, feet, shoulders, hands, elbows and back. In the words of Rob Siegel, Director of Operations for ENSA Access & Rescue, a safety training company for high-access mechanics and technicians, "The safety culture in this industry is still young." Proof of his claim can be seen in the fact that specific OSHA regulations for working in an environment such as wind towers have still yet to be established. Additionally, the real statistics of injury while on-the-job in wind energy is undisclosed information. It is unknown how many of these injuries are career-ending and contribute toward higher rates of employee turnover and reduced productivity. As planning continues for future wind parks, implementing the latest safety features while minimizing costs will be a crucial factor.

Two Types of High-Access Systems
The future of tower maintenance in wind energy includes the implementation of high-access systems in every tower to support service crews in reaching the necessary work height as quickly and efficiently as possible. There are currently two main approaches toward high-access systems in wind towers. Most newly-constructed wind parks will incorporate a service lift in each tower. Ladder-guided or wire rope-guided lift systems offer the highest level of efficiency in tower maintenance and provide, along with a host of additional safety features, the most secure climbing conditions available. Depending on the manufacturer, these systems can be installed on both open and closed towers as well as on land, near-shore or at sea in off-shore towers.

The prevalence of climbing assistance equipment is very high in Europe, to the point of becoming a standard feature in wind towers. However, high-access systems are still a novelty for the US industry, where the standard is still a basic ladder. The overwhelming majority of previously constructed wind towers have little to no climbing support for technicians. In most cases, retro-fitting service lifts into pre-existing towers would require expensive alterations to be made inside the tower and would not be a cost-effective or feasible option in the existing US wind parks. However, a ladder climbing system is the second, more flexible, high-access system which can be more readily retro-fitted onto existing ladders within towers.

There are a handful of approaches to ladder climbing systems. One example is a counterweight method, helping to balance the weight of the climber on the reverse side of the ladder. A less space consuming option is to assist the climber to ascend with an adjustable traction force. Attached to the standard ladder, this type of system pulls a rope which runs around the top end of the ladder, in order to support the climber. Both types of systems allow for an automatic stop-and-go adjustment to the climber's motions. However, an adjustable traction force system allows a second climber to ascend immediately once the first climber is at the necessary height for maintenance. This is an additional benefit compared to a counterweight system where the counterweight must return to the start position before a second climber can begin to ascend.

The purpose of a ladder climbing system is to reduce the weight of the climber. The amount of weight reduction experienced by the climber depends on the type of system used. Technicians must carry their tools with them when climbing. The use of a ladder climbing system allows for an increase in the climber's carry-on equipment weight, an estimated forty pounds, without increasing the weight felt by the technician. This creates a drastic reduction in the strain on a climber's joints and muscles. Climbing times are significantly reduced because climbers need fewer or shorter breaks and experience less physical fatigue. This heavily impacts worker productivity. Currently, without high-access support, service crews can manage the maintenance of an average of four towers per day. With the assistance of high-access systems, this could increase considerably.

Cost Saving Benefits of Implementing High-Access Systems
Climbing support and lift systems benefit the industry by lowering the maintenance time necessary per tower and by increasing the productivity and effectiveness of a single service crew. Lift systems have the highest safety standards. Due to minimized accident and health risks, the installation of climbing support or lift systems should result in insurance cost savings. This is expected to happen when insurance companies see proof of the improved safety conditions through a decrease in accident claims.

Additional benefits that are specific to service lifts include not only eliminating time-consuming climbing and physical exertion of the maintenance workers, but also the ability to vertically transport two service people at the same time. In fact, certain manufacturers are offering service lifts that can also act as a material hoist. This eliminates the need for specialty equipment for hoisting heavy or large materials to high service sites. Over the life of a tower, the benefits of increased efficiency and productivity combined with the safety and security provided by high-access systems will result in a worthwhile return on investment.

High-access systems also greatly improve the work environment by decreasing physical strain on employees and virtually eliminating climbing-related accident risks. This benefit alone can increase worker lifespan with the company. Based on the history of wind power in the US, we can estimate that the population of highly skilled labor with the greatest years of experience is in the age-range of forty to fifty years old. Incorporating a ladder-climber into already existing towers could greatly increase the chances of retaining skilled labor for an additional ten to twenty years. Employee retention can be a significant cost savings, insuring a consistent skill set and institutional memory among employees and, thus, less time spent training new hires. The exact numbers are undisclosed, but wind parks and wind tower service providers tend to experience high personnel rotation due to the physical demands of climbing towers without high-access support. The integration of climbing support solutions helps to keep experts with the company. Aside from maintaining a more experienced staff, the benefits of employee retention includes, less time spent interviewing, hiring and training replacement workers.

Future of Wind Energy in the US
The landscape of wind energy is affected by several influences. As the new federal administration begins to take action the industry will see more changes. Looking at the status of wind energy outside of the US, as in Europe for example, tower heights are continuously increasing and Megawatt production capabilities are steadily growing. It is reasonable to assume that the future of wind energy will strive for larger, stronger towers, producing maximum Megawatts. Higher towers with larger components will necessitate service lifts as a standard. And once high-access systems are established in newer towers, retro-fitting pre-existing towers with ladder climbing systems will most likely be necessary to maintain a competitive advantage and keep skilled labor with the company. Reduced strain on employees decreases worker error and is an overall benefit to the company. Making the investment in high-access systems will save money while adequately preparing wind parks for the future of wind energy.

About GORACON:

GORACON Windpower Access Systems, LP is a full solution provider of climb, lift and platform systems. Years of experience result in high quality and proven durability of GORACON's products. As a leader of innovation in the industry, GORACON provides custom designed solutions and integrates individual customer demands into the product development process. The company's wide product range covers all access needs in the high access sectors, in particular the wind power industry.

GORACON's product line includes wire rope and ladder guided service lifts, ladder climbers, tower assembly platforms, maintenance platforms, modular platforms and blade lifts, all of which meet the highest national and industrial standards and requirements.